WO2021251502A1 - Thermoforming device and thermoforming method - Google Patents

Thermoforming device and thermoforming method Download PDF

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Publication number
WO2021251502A1
WO2021251502A1 PCT/JP2021/022473 JP2021022473W WO2021251502A1 WO 2021251502 A1 WO2021251502 A1 WO 2021251502A1 JP 2021022473 W JP2021022473 W JP 2021022473W WO 2021251502 A1 WO2021251502 A1 WO 2021251502A1
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WO
WIPO (PCT)
Prior art keywords
mold
molding
sheet
lower mold
upper mold
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PCT/JP2021/022473
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French (fr)
Japanese (ja)
Inventor
憲一 溝口
章伍 高井
一典 寺本
Original Assignee
株式会社浅野研究所
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Application filed by 株式会社浅野研究所 filed Critical 株式会社浅野研究所
Priority to CN202180022136.0A priority Critical patent/CN115298013A/en
Publication of WO2021251502A1 publication Critical patent/WO2021251502A1/en

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/08Deep drawing or matched-mould forming, i.e. using mechanical means only
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26Component parts, details or accessories; Auxiliary operations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26Component parts, details or accessories; Auxiliary operations
    • B29C51/30Moulds
    • B29C51/38Opening, closing or clamping means

Definitions

  • the present invention relates to a technique capable of molding a resin molded sheet using a thermoforming apparatus without leaving a strain generated during molding of the resin molded sheet at a specific portion of the molded product.
  • thermoforming device When molding a resin sheet using a thermoforming device, there is a method of pressurizing using an upper mold and a lower mold as molding dies to deform and mold the heated resin sheet. Molding is performed by sandwiching a resin sheet softened by heating between an upper mold and a lower mold and pressurizing it. For example, it is a method as shown in Patent Document 1.
  • Patent Document 1 discloses a technique relating to a mold clamping device and a mold clamping method.
  • the sheet sandwiched between the upper edge of the frame and the lower edge of the frame is heated and softened, and the plug corresponding to the upper mold is brought close to the female mold corresponding to the lower mold, and the resin molded sheet held between them. It is configured to mold. At this time, the resin molded sheet is held so as not to move by pressing the resin molded sheet against the lower table side by the gripping member provided on the upper table side.
  • a molded product is used as a cover for a car navigation system attached to an automobile, and this cover has a transparent part used as an operation window. Even if the distortion of the molded product cannot be visually confirmed, directional distortion may be formed inside the molded product, and when you look at the car navigation screen through a lens that uses polarized glasses such as sunglasses, it is one of the displays. The applicant has confirmed that there are cases where the part appears to be missing. Further, when an LED backlight or the like is used for the display screen, interference fringes may appear due to the influence of internal distortion. Since there are cases where the distortion remaining inside the molded product becomes a problem in this way, countermeasures are required.
  • an object of the present invention is to solve such a problem and to provide a thermoforming apparatus and a thermoforming method capable of forming so that internal strain does not remain in a specific portion.
  • thermoforming apparatus according to one aspect of the present invention has the following features.
  • thermoforming apparatus having an upper mold and a lower mold as a molding mold and sandwiching a heated resin sheet between the upper mold and the lower mold, either the upper mold or the lower mold is used. It has a pressing means provided so as to protrude from the molding surface on one side, and the pressing means forms a specific portion of the resin sheet that becomes a part of the product after molding on the other side of the molding mold. It has a function of sandwiching with a surface, and is characterized in that a portion other than the specific portion of the resin sheet is sandwiched between the upper mold and the lower mold to form the resin sheet.
  • the specific portion is a transparent portion when the resin sheet becomes a product.
  • thermoforming apparatus includes a drive mechanism for raising and lowering at least one of the upper mold and the lower mold, and a control device for controlling the drive mechanism. With the lower mold closed, position control or torque control is performed by a control device that controls the drive mechanism to control the position of the lower mold with respect to the upper mold.
  • the position of the lower mold with respect to the upper mold can be controlled by the drive mechanism according to the embodiment described in (3) above, the clearance of the lower mold with respect to the upper mold when the mold is closed is controlled, and the molding condition of the molded product is adjusted. can do.
  • the raising and lowering of the upper die or the lower die by the drive mechanism has a function of fixing one of the upper die or the lower die and bringing the other close to each other, or both close to each other. This makes it possible to control the clearance of the lower mold with respect to the upper mold, for example, according to the material and thickness of the resin sheet. By doing so, it is possible to adjust the finished product of the molded product, and thus it is possible to improve the molding accuracy.
  • thermoforming apparatus In the thermoforming apparatus according to (1), the specific portion is characterized in that an air pool is likely to occur during molding.
  • thermoforming method according to another aspect of the present invention has the following features.
  • thermoforming method in which an upper mold and a lower mold are provided as a molding mold and a heated resin sheet is sandwiched between the upper mold and the lower mold, either the upper mold or the lower mold is used.
  • a specific portion of the resin sheet that is a part of the molded product after molding is sandwiched between the pressing means provided so as to protrude from the molding surface on one side and the molding surface of the molding mold on the other side. It is characterized in that the resin sheet is formed by sandwiching a portion other than the specific portion of the resin sheet between the upper mold and the lower mold.
  • the molded product after molding can suppress the occurrence of internal strain in a specific portion pressed by the pressing means. can. Therefore, as in the embodiment of the thermoforming apparatus described in (2), when the specific portion is a transparent portion, internal distortion, interference fringes, etc. in the specific portion pressed by the pressing means may occur. It can be prevented from occurring. Therefore, it is possible to make a product in which the transparent portion remains transparent.
  • thermoforming apparatus of this embodiment It is a side view which shows the whole outline of the thermoforming apparatus of this embodiment. It is a side view of the molding part of this embodiment. It is a perspective view explaining the drive system of the lower table of this embodiment. It is a perspective view explaining the drive system of the upper table of this embodiment. It is a side sectional view of the present embodiment in a state where the upper mold and the lower mold are close to each other. It is a schematic block diagram of the control about the molded part of this embodiment. It is a schematic diagram which shows the state that the resin molded sheet is sandwiched between the sheet pressing part and the lower mold of this embodiment. It is a schematic diagram which shows the state that the upper mold and the lower mold are brought close to each other while being pressed by the sheet pressing portion of this embodiment.
  • FIG. 1 is a schematic side view briefly illustrating the entire thermoforming apparatus 10 of the present embodiment.
  • the thermoforming apparatus 10 includes a sheet heating unit 20 and a molding unit 30.
  • the sheet heating unit 20 is a place for heating the resin molded sheet S.
  • the resin molded sheet S cut in advance for one shot is clamped by the transfer device 50 by a clamping function (not shown) and moved to the sheet heating unit 20.
  • the resin molded sheet S is heated and softened.
  • the resin molding sheet S is conveyed to the molding unit 30 to perform molding.
  • the sheet heating unit 20 is provided with an upper heater unit 21 and a lower heater unit 22 as a pair of heater units.
  • the heating elements arranged in the upper heater unit 21 and the lower heater unit 22 are energized.
  • the heating temperature is appropriately set by the material of the resin molded sheet S.
  • the molding unit 30 is provided with an upper table 31 and a lower table 32 that are moved up and down.
  • the upper table 31 and the lower table 32 are configured to move up and down by ball screws (second ball screw 34 and first ball screw 35) described later, and the upper mold 37 and the lower table provided inside the upper table 31.
  • ball screws second ball screw 34 and first ball screw 35
  • FIG. 2 shows a side view of the molded portion 30.
  • the molding portion 30 is provided with a frame 36, and the upper table 31 and the lower table 32 are moved up and down in the frame 36.
  • a guide rail 36a which is long in the vertical direction and has a length corresponding to the elevating stroke of the lower table 32 is provided.
  • FIG. 3 shows a perspective view of the drive system of the lower table 32.
  • the lower table 32 is provided with fitting portions 32a at its four corners.
  • the fitting portion 32a has a function of guiding the raising and lowering of the lower table 32 by fitting with the guide rail 36a shown in FIG.
  • the second ball screw 34 is arranged diagonally to the lower table 32.
  • the second ball screw 34 is rotatably fixed to the frame 36 and is arranged so as to penetrate the lower table 32.
  • a nut 34b is fixed to the lower table 32 at a position where the second ball screw 34 penetrates, and the nut 34b and the second ball screw 34 mesh with each other.
  • a second pulley 34a is attached to the upper end of the second ball screw 34, and the rotational driving force of the second servomotor 61 is transmitted to each of the second pulleys 34a via the second timing belt 34c. Therefore, the lower table 32 is configured to move up and down by the rotational drive of the second servomotor 61.
  • a lower die 33 is fixed to the center of the lower table 32, and the lower die 33 also moves up and down as the lower table 32 moves up and down.
  • FIG. 4 shows a perspective view of the drive system of the upper table 31 extracted.
  • Gripping members 31a are provided at the four corners of the upper table 31.
  • the gripping member 31a engages with the guide rail 36b provided on the frame 36 shown in FIG. 2 and slides to guide the raising and lowering of the upper table 31.
  • the vertical driving force of the upper table 31 is obtained by the first servomotor 60, and the rotational force of the first servomotor 60 is transmitted to the first ball screw 35 by the first timing belt 35c as shown in FIG.
  • the upper table 31 is raised and lowered.
  • a first pulley 35a is fixed to the end of the first ball screw 35.
  • An upper die 37 is fixed to the lower surface of the upper table 31.
  • FIG. 5 shows a side sectional view of the upper die 37 and the lower die 33 in close proximity to each other.
  • the upper die 37 and the lower die 33 in the figure are closer to each other than the retreat positions of the upper die 37 and the lower die 33.
  • the lower mold 33 is configured to abut against the upper mold 37 with the resin molded sheet S sandwiched between them, and the upper mold 37 is provided with a sheet pressing portion 37a.
  • the seat pressing portion 37a is engaged with the upper mold 37 via a spring 37b, and is guided by a shaft (not shown) arranged in the center of the spring 37b, so that the upper mold is as shown in FIG. 7D described later.
  • the sheet pressing portion 37a is housed in the recess 37c provided in the upper mold 37.
  • FIG. 6 shows a schematic configuration of control regarding the molded portion 30.
  • a servomotor control unit 91, an input unit 94, and an output unit 95 are connected to the programmable logic controller (hereinafter referred to as PLC) 90.
  • the first servomotor 60 and the second servomotor 61 are connected to the servomotor control unit 91, respectively.
  • a first encoder 70 is connected to the first servomotor 60
  • a second encoder 71 is connected to the second servomotor 61
  • the first encoder 70 and the second encoder 71 are connected to the PLC 90, respectively.
  • the output unit 95 includes a display or the like provided on an operation panel (not shown), and displays a status such as an error.
  • the input unit 94 includes buttons provided on an operation panel (not shown), and can input various data and the like.
  • the operation panel is a touch panel system and does not prevent the input unit 94 and the output unit 95 from being combined. Further, the input unit 94 may be provided with a button for operation separately.
  • the servomotor control unit 91 drives and controls the first servomotor 60 and the second servomotor 61.
  • a device provided in the molding unit 30 is connected to the PLC 90, the description thereof is omitted because it is not directly related to the present invention.
  • FIG. 7A to 7D schematically show how the resin molded sheet S is molded by the upper mold 37 and the lower mold 33.
  • the resin molded sheet S is pressed against the lower mold 33 by the sheet pressing portion 37a provided on the upper mold 37.
  • the sheet pressing portion 37a is urged by a spring 37b, and the resin molded sheet S is fixed so as not to move due to the pressing force.
  • one end of the resin molded sheet S is clamped by the transport device 50.
  • the resin molded sheet S is deformed by advancing the upper mold 37 with respect to the lower mold 33.
  • the upper mold 37 and the lower mold 33 are advanced to a position where they are in close contact with each other via the resin molded sheet S, thereby pressurizing and deforming the resin molded sheet S. In this way, the resin molded sheet S is molded into the molded product M by the upper mold 37 and the lower mold 33.
  • thermoforming apparatus 10 of the present embodiment Since the thermoforming apparatus 10 of the present embodiment has the above configuration, it exhibits the following actions and effects.
  • thermoforming apparatus 10 provided with an upper mold 37 and a lower mold 33 as a molding mold and sandwiching a heated resin molding sheet S between the upper mold 37 and the lower mold 33, in which the upper mold 37 or the lower mold 33 is formed.
  • a sheet pressing portion 37a which is a pressing means provided so as to protrude from the molded surface on either one of the two, is provided, and the sheet pressing portion 37a becomes a part of the molded product M after molding in the resin molded sheet S.
  • a specific portion (transparent portion M1 described later) is pressed so as to be sandwiched between the molding surface of the molding die on the other side (in the present embodiment, the lower surface of the sheet pressing portion 37a provided on the upper die 37 and the upper surface of the lower die 33 are pressed. (Holding so as to be sandwiched), the resin molded sheet S is formed by sandwiching the resin molded sheet S with the upper mold 37 and the lower mold 33 except for a specific portion.
  • FIGS. 8A to 8D are diagrams schematically showing how the resin molded sheet S is molded by the upper mold 137 and the lower mold 133 prepared for comparison.
  • the resin molding sheet S is molded by the upper mold 137 and the lower mold 133.
  • the upper mold 137 and the lower mold 133 play the same role as the upper mold 37 and the lower mold 33 of the present embodiment. The same applies to the point that one end is clamped by the moving device 150.
  • the resin molded sheet S is molded by bringing the upper mold 137 and the lower mold 133 close to each other as in the present embodiment. However, as shown in FIG. 8B, the resin molded sheet S abuts on the upper die 137 at the point P1 and abuts on the lower die 133 at the point P3 to form a point P2 floating from the lower die 133.
  • FIG. 9 schematically shows a perspective view when molding a resin molded sheet using an upper mold and a lower mold.
  • the molded product M is provided with a transparent portion M1.
  • a display screen is arranged behind the molded product M, so that the transparent portion M1 is provided. It becomes the window part.
  • the transparent portion M1 is first pressed against the lower mold 33 by the sheet pressing portion 37a, and the upper mold 37 is brought close to the lower mold 33 while being held (actually, the upper mold 37).
  • the mold 37 is lowered by driving the first servomotor 60, and the lower mold 33 is raised by driving the second servomotor 61, so that the mold 37 is controlled to be close to each other).
  • the upper mold 37 and the lower mold 33 are brought into close contact with each other via the resin molding sheet S to form the molded product M.
  • the transparent portion M1 can be firmly held by applying pressure to the upper surface of the lower mold 33 at the sheet pressing portion 37a first, and FIGS. 7B and 7C And when the resin molded sheet S is deformed, the transparent portion M1 does not move. Therefore, the floating as shown at the point P2 as shown in FIGS. 8B and 8C cannot be performed. Therefore, the meat is molded without being pulled or wrinkled from the transparent portion M1, and when the state shown in FIG. 7D is reached, the transparent portion M1 is molded in a state where internal strain is not accumulated. It will be possible.
  • the internal strain is formed in a directional manner, so that it may exhibit polarization with respect to transmitted light.
  • sunglasses using a polarized lens when sunglasses using a polarized lens are used, it is transparent. A part of the display screen that can be seen through the portion M1 may appear as a defect.
  • such a problem can be solved by molding with the upper mold 37 and the lower mold 33 in a state where the transparent portion M1 is pressed by the sheet pressing portion 37a.
  • the resin molded sheet S is molded in a state of being pressed by the sheet pressing portion 37a, even if the shape is such that air accumulation is likely to occur in this portion, the resin molded sheet S is pressed by the sheet pressing portion 37a. It is possible to prevent the formation of air pools. Therefore, it is possible to prevent the appearance from being deteriorated due to the generation of air pool.
  • the transparent portion M1 is used as a window when it is made into a product, it is possible to prevent an appearance defect due to the occurrence of air accumulation even if the structure is such that air accumulation is likely to occur in this portion.
  • thermoforming apparatus 10 performs position control or torque control, it is possible to control the clearance between the upper die 37 and the lower die 33 to an appropriate level.
  • This includes a first servomotor 60 corresponding to a first drive mechanism for raising the upper die 37, a second servomotor 61 corresponding to a second drive mechanism for lowering the lower die 33, a first servomotor 60, and a first servomotor 60.
  • Servo motor control unit 91 which is a control device for controlling the servo motor 61, and controls the first servo motor 60 and the second servo motor 61 with the upper die 37 and the lower die 33 closed. This is because the position control or torque control is performed by the 91 to control the position of the lower die 33 with respect to the upper die 37.
  • the first servomotor 60 and the second servomotor 61 are used to drive while performing feedback control, respectively.
  • the ball screw (first ball screw 35 and second ball screw 34) is rotated by the rotational drive of the servo motors (first servo motor 60 and second servo motor 61), and as a result, the upper table 31 and the lower table 32 are moved up and down. It is a structure that can be done.
  • the first servomotor 60 can execute position control using the position of the upper table 31 as a feedback element and torque control using the generated torque as a feedback element.
  • position control and torque control can be performed on the lower table 32 as well.
  • position control or torque control can be performed at the time of mold clamping, and the clearance between the upper mold 37 and the lower mold 33 can be controlled. It may be desirable to change the mold clamping pressure depending on the thickness of the resin molded sheet S, the properties of the material, the heating conditions of the upper mold 37 and the lower mold 33, and the like. Although the resin molded sheet S is in a state of being preheated by the heating unit 20 and softened in advance, there are cases where springback occurs after the molding process. In such a case, by performing position control or torque control on the upper mold 37 and the lower mold 33, it is possible to contribute to improving the molding accuracy of the molded product M.
  • the present invention is not limited to this, and various changes can be made without departing from the spirit of the present invention.
  • the seat pressing portion 37a is provided on the upper mold 37, but it may be better to provide the seat pressing portion 37a on the lower mold 33 depending on the place to be pressed, so that such a change is not hindered.
  • the spring 37b is provided between the upper die 37 and the seat pressing portion 37a to urge the resin molded sheet S.
  • an urging means using a cylinder or a motor may be used. It does not prevent the adoption of the used urging means.
  • the upper die 37 (or the lower die 33) and the sheet pressing portion 37a may be separated from each other.
  • the ball screw (first ball screw 35 and second ball screw 34) is driven by the rotational drive of the servomotor (first servomotor 60 and second servomotor 61).
  • the method is to be driven via a timing belt (first timing belt 35c and second timing belt 34c) which is a transmission means and a pulley or the like (first pulley 35a and second pulley 34a), but the method is limited to this.
  • a timing belt first timing belt 35c and second timing belt 34c
  • first pulley 35a and second pulley 34a which is a transmission means and a pulley or the like
  • it does not prevent the vehicle from being driven by using a gear or a cam as a power transmission means.
  • it does not prevent the cylinder and the crank mechanism from being used together for the mold clamping between the upper mold 37 and the lower mold 33.
  • thermoforming apparatus 10 for driving the upper table 31 and the lower table 32 has been described, it is fixed on one side as necessary, that is, either the upper table 31 or the lower table 32 is fixed and only the other is driven. It may be a method.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

A thermoforming device (10) comprising an upper mold (37) and a lower mold (33) as molding dies and whereby a resin molding sheet (S) is interposed between the upper mold (37) and the lower mold (33) and molded. The thermoforming device (10) has a sheet pressing section (37a) provided so as to protrude from the molding surface of either the upper mold (37) or the lower mold (33). The sheet pressing section (37a) has a function that, together with the molding surface of the other molding die, sandwiches a transparent section (M1) which is a section of the resin molding sheet (S) that forms part of the molded product (M) after molding. The resin molding sheet (S) is molded by the rest of the resin molding sheet (S), other than the transparent section (M1), being sandwiched by the upper mold (37) and the lower mold (33).

Description

熱成形装置及び熱成形方法Thermoforming equipment and thermoforming method
 本発明は、熱成形装置を用いて樹脂成形シートを成形するにあたって、成形品の特定の部位に樹脂成形シート成形時に生じる歪みを残さずに成形可能な技術に関する。 The present invention relates to a technique capable of molding a resin molded sheet using a thermoforming apparatus without leaving a strain generated during molding of the resin molded sheet at a specific portion of the molded product.
 熱成形装置を用いて樹脂製のシートを成形するにあたって、成形型として上型と下型を用いて加圧し、加熱した樹脂製シートを変形させ成形する手法がある。加熱して軟化した樹脂製シートを上型と下型で挟んで加圧することにより成形を行う。例えば特許文献1に示すような方法である。 When molding a resin sheet using a thermoforming device, there is a method of pressurizing using an upper mold and a lower mold as molding dies to deform and mold the heated resin sheet. Molding is performed by sandwiching a resin sheet softened by heating between an upper mold and a lower mold and pressurizing it. For example, it is a method as shown in Patent Document 1.
 特許文献1には、型締め装置および型締め方法に関する技術が開示されている。枠上縁部と枠下縁部に挟持されたシートを加熱して軟化させ、下型に相当する雌型に対して上型に相当するプラグを近接させ、その間に保持している樹脂成形シートを成形する構成となっている。この際に上テーブル側に備えた把持部材によって下テーブル側に樹脂成形シートを押しつけるようにすることで、樹脂成形シートが動かないように保持している。 Patent Document 1 discloses a technique relating to a mold clamping device and a mold clamping method. The sheet sandwiched between the upper edge of the frame and the lower edge of the frame is heated and softened, and the plug corresponding to the upper mold is brought close to the female mold corresponding to the lower mold, and the resin molded sheet held between them. It is configured to mold. At this time, the resin molded sheet is held so as not to move by pressing the resin molded sheet against the lower table side by the gripping member provided on the upper table side.
特許第3602051号公報Japanese Patent No. 3602051
 しかし、特許文献1に記載の技術を用いた場合であっても、成形型の形状によっては樹脂製シートの成形をする際に成形品の内部に歪が生じてしまい、その結果、その成形品を使った製品の機能に影響してしまう問題があった。例えば、成形に用いる樹脂製シートが厚手のシートである場合、金型を用いて成形するため狙った形状に成形はされるが、内部に歪みが残る問題が生じる。この内部に残った歪みが、成形品が製品となった場合にその製品の機能に影響する懸念がある。 However, even when the technique described in Patent Document 1 is used, depending on the shape of the molding die, distortion may occur inside the molded product when molding the resin sheet, and as a result, the molded product may be distorted. There was a problem that it affected the function of the product using. For example, when the resin sheet used for molding is a thick sheet, it is molded into a target shape because it is molded using a mold, but there is a problem that distortion remains inside. There is a concern that the strain remaining inside may affect the function of the product when the molded product becomes a product.
 具体的な例を挙げると、例えば、成形品が自動車に取り付けるカーナビのカバーに使われ、このカバーに操作窓として使う透明部分があるような場合である。目視では成形品の歪みが確認できなくとも、成形品内部には方向性を持った歪みが形成されることがあり、サングラスなど偏光グラスを採用するレンズを通してカーナビの画面を見ると、表示の一部が欠損して見えるケースがあることを出願人は確認している。また、表示画面にLEDバックライトなどを採用している場合などには、内部歪みの影響によって干渉縞が現れることがある。このように成形品の内部に残った歪みが問題になるケースがあるため、対策が求められている。 To give a specific example, for example, a molded product is used as a cover for a car navigation system attached to an automobile, and this cover has a transparent part used as an operation window. Even if the distortion of the molded product cannot be visually confirmed, directional distortion may be formed inside the molded product, and when you look at the car navigation screen through a lens that uses polarized glasses such as sunglasses, it is one of the displays. The applicant has confirmed that there are cases where the part appears to be missing. Further, when an LED backlight or the like is used for the display screen, interference fringes may appear due to the influence of internal distortion. Since there are cases where the distortion remaining inside the molded product becomes a problem in this way, countermeasures are required.
 そこで、本発明はこの様な課題を解決し、内部の歪みが特定部分に残らないような成形が可能な熱成形装置及び熱成形方法の提供を目的とする。 Therefore, an object of the present invention is to solve such a problem and to provide a thermoforming apparatus and a thermoforming method capable of forming so that internal strain does not remain in a specific portion.
 前記目的を達成するために、本発明の一態様による熱成形装置は、以下のような特徴を有する。 In order to achieve the above object, the thermoforming apparatus according to one aspect of the present invention has the following features.
(1)成形型として上型と下型を備え、前記上型と前記下型の間に加熱した樹脂製シートを挟んで成形する熱成形装置において、前記上型または前記下型のうちいずれか一方側の成形面から突出するように備えられる押圧手段を有し、前記押圧手段は、前記樹脂製シートのうち成形後の製品の一部となる特定の部位を他方側の前記成形型の成形面と挟み込む機能を有し、前記樹脂製シートのうち前記特定の部位以外を前記上型と前記下型によって挟み込み、前記樹脂製シートを成形すること、を特徴とする。 (1) In a thermoforming apparatus having an upper mold and a lower mold as a molding mold and sandwiching a heated resin sheet between the upper mold and the lower mold, either the upper mold or the lower mold is used. It has a pressing means provided so as to protrude from the molding surface on one side, and the pressing means forms a specific portion of the resin sheet that becomes a part of the product after molding on the other side of the molding mold. It has a function of sandwiching with a surface, and is characterized in that a portion other than the specific portion of the resin sheet is sandwiched between the upper mold and the lower mold to form the resin sheet.
(2)(1)に記載の熱成形装置において、前記特定の部位が、前記樹脂製シートが製品となった時に透明な部分であること、を特徴とする。 (2) In the thermoforming apparatus according to (1), the specific portion is a transparent portion when the resin sheet becomes a product.
 上記(1)に記載の態様により、樹脂製シートのうち特定の部位を押さえた状態で、成形型によって成形するという手法を採用することで、押さえた部分の内部に内部歪みを溜めにくくすることができる。このため、(2)に記載の態様のように、特定の部位が透明な部分であった場合には、歪みの影響で光が偏光して透過するなどし、製品として問題となる。このため、特定の部分を押圧手段によって最初に押さえてから成形をすることで、内部の歪み、干渉縞などの発生を防ぐことができる。したがって、透明部分は透明のままの製品を作ることができる。 According to the embodiment described in (1) above, by adopting a method of molding with a molding die while pressing a specific portion of the resin sheet, it is difficult to accumulate internal strain inside the pressed portion. Can be done. Therefore, as in the embodiment described in (2), when a specific portion is a transparent portion, light is polarized and transmitted due to the influence of distortion, which causes a problem as a product. Therefore, by first pressing the specific portion with the pressing means and then molding, it is possible to prevent the occurrence of internal distortion, interference fringes, and the like. Therefore, it is possible to make a product in which the transparent portion remains transparent.
(3)(1)または(2)に記載の熱成形装置において、前記上型または前記下型の少なくとも一方を昇降させる駆動機構と、前記駆動機構を制御する制御装置を備え、前記上型と前記下型を閉じた状態で、前記駆動機構を制御する制御装置によって位置制御またはトルク制御を行い、前記上型に対する前記下型の位置を制御すること、を特徴とする。 (3) The thermoforming apparatus according to (1) or (2) includes a drive mechanism for raising and lowering at least one of the upper mold and the lower mold, and a control device for controlling the drive mechanism. With the lower mold closed, position control or torque control is performed by a control device that controls the drive mechanism to control the position of the lower mold with respect to the upper mold.
 上記(3)に記載の態様により、駆動機構によって上型に対する下型の位置を制御することができるため、型閉じ時の上型に対する下型のクリアランスをコントロールし、成形品の成形状況を調整することができる。ここで、駆動機構による上型または下型の昇降は、上型または下型の一方を固定して他方を近接させる、或いは両方を近接させる機能を有する。これによって、例えば樹脂製シートの素材や厚みに合わせて上型に対する下型のクリアランスをコントロールすることができる。このようにすることで、成形品のできあがりを調整することができるため、成形精度を向上させることが可能である。 Since the position of the lower mold with respect to the upper mold can be controlled by the drive mechanism according to the embodiment described in (3) above, the clearance of the lower mold with respect to the upper mold when the mold is closed is controlled, and the molding condition of the molded product is adjusted. can do. Here, the raising and lowering of the upper die or the lower die by the drive mechanism has a function of fixing one of the upper die or the lower die and bringing the other close to each other, or both close to each other. This makes it possible to control the clearance of the lower mold with respect to the upper mold, for example, according to the material and thickness of the resin sheet. By doing so, it is possible to adjust the finished product of the molded product, and thus it is possible to improve the molding accuracy.
(4)(1)に記載の熱成形装置において、前記特定の部位が、成形時にエア溜まりを生じやすい部分であること、を特徴とする。 (4) In the thermoforming apparatus according to (1), the specific portion is characterized in that an air pool is likely to occur during molding.
 上記(4)に記載の態様により、成形時にエア溜まりを生じやすい部分を押圧手段によって押さえ込むことで、エア溜まりによる不良発生の防止を実現することができる。成形型の形状によっては、例えばお椀状に凹んだ形状であった場合に、その底部分に空気が溜まりやすいことがあるが、そうした場合に先に底部分に押圧手段にて押さえて成形することで、不良品の発生を防止することができる。 According to the aspect described in (4) above, it is possible to prevent the occurrence of defects due to the air accumulation by pressing the portion where the air accumulation is likely to occur during molding by the pressing means. Depending on the shape of the molding mold, for example, if the shape is recessed like a bowl, air may easily collect in the bottom part, but in such a case, first press the bottom part with a pressing means to mold. Therefore, it is possible to prevent the occurrence of defective products.
 また、前記目的を達成するために、本発明の別の態様による熱成形方法は、以下のような特徴を有する。 Further, in order to achieve the above object, the thermoforming method according to another aspect of the present invention has the following features.
(5)成形型として上型と下型を備え、前記上型と前記下型の間に加熱した樹脂製シートを挟んで成形する熱成形方法において、前記上型または前記下型のうちいずれか一方側の成形面から突出するように備えられる押圧手段と、他方側の前記成形型の成形面とで、前記樹脂製シートのうち成形後の成形品の一部となる特定の部位を挟み込み、前記上型と前記下型とで、前記樹脂製シートのうち前記特定の部位以外を挟み込み、前記樹脂製シートを成形すること、を特徴とする。 (5) In a thermoforming method in which an upper mold and a lower mold are provided as a molding mold and a heated resin sheet is sandwiched between the upper mold and the lower mold, either the upper mold or the lower mold is used. A specific portion of the resin sheet that is a part of the molded product after molding is sandwiched between the pressing means provided so as to protrude from the molding surface on one side and the molding surface of the molding mold on the other side. It is characterized in that the resin sheet is formed by sandwiching a portion other than the specific portion of the resin sheet between the upper mold and the lower mold.
 上記(5)に記載の態様により、(1)に記載の熱成形装置の態様と同様に、成形後の成形品が、押圧手段によって押さえられた特定の部位における内部歪みの発生を抑えることができる。このため、(2)に記載の熱成形装置の態様のように、特定の部位が透明な部分であった場合には、押圧手段によって押さえられた特定の部位における内部の歪み、干渉縞などの発生を防ぐことができる。したがって、透明部分は透明のままの製品を作ることができる。 According to the embodiment described in (5) above, similarly to the embodiment of the thermoforming apparatus described in (1), the molded product after molding can suppress the occurrence of internal strain in a specific portion pressed by the pressing means. can. Therefore, as in the embodiment of the thermoforming apparatus described in (2), when the specific portion is a transparent portion, internal distortion, interference fringes, etc. in the specific portion pressed by the pressing means may occur. It can be prevented from occurring. Therefore, it is possible to make a product in which the transparent portion remains transparent.
本実施形態の、熱成形装置の全体概略を示す側面図である。It is a side view which shows the whole outline of the thermoforming apparatus of this embodiment. 本実施形態の、成形部の側面図である。It is a side view of the molding part of this embodiment. 本実施形態の、下側テーブルの駆動系を説明する斜視図である。It is a perspective view explaining the drive system of the lower table of this embodiment. 本実施形態の、上側テーブルの駆動系を説明する斜視図である。It is a perspective view explaining the drive system of the upper table of this embodiment. 本実施形態の、上型と下型が近接した状態の側面断面図である。It is a side sectional view of the present embodiment in a state where the upper mold and the lower mold are close to each other. 本実施形態の、成形部に関する制御の概略構成図である。It is a schematic block diagram of the control about the molded part of this embodiment. 本実施形態の、シート押圧部と下型で樹脂成形シートを挟んだ様子を示す模式図である。It is a schematic diagram which shows the state that the resin molded sheet is sandwiched between the sheet pressing part and the lower mold of this embodiment. 本実施形態の、シート押圧部で押さえながら上型と下型を近接させた様子を示す模式図である。It is a schematic diagram which shows the state that the upper mold and the lower mold are brought close to each other while being pressed by the sheet pressing portion of this embodiment. 本実施形態の、上型と下型をさらに近接させた様子を示す模式図である。It is a schematic diagram which shows the state that the upper mold and the lower mold are further brought close to each other in this embodiment. 本実施形態の、上型と下型を、樹脂成形シートを介して密着させた様子を示す模式図である。It is a schematic diagram which shows the state that the upper mold and the lower mold of this embodiment are brought into close contact with each other through a resin molded sheet. 比較のために用意した、上型と下型で樹脂成形シートを挟む様子を示す模式図である。It is a schematic diagram which showed the state which sandwiched the resin molded sheet between the upper mold and the lower mold prepared for comparison. 比較のために用意した、上型と下型を近接した様子を示す模式図である。It is a schematic diagram which showed the state which the upper mold and the lower mold were close to each other prepared for comparison. 比較のために用意した、上型と下型を更に近接させた様子を示す模式図である。It is a schematic diagram which showed the state which made the upper mold and the lower mold closer to each other prepared for comparison. 比較のために用意した、上型と下型を、樹脂成形シートを介して密着させた様子を示す模式図である。It is a schematic diagram which shows the state that the upper mold and the lower mold prepared for comparison were brought into close contact with each other through a resin molded sheet. 本実施形態の、樹脂成形シートの成形を行う様子を模式的に示した斜視図である。It is a perspective view schematically showing the state of molding a resin molded sheet of this embodiment.
[装置構成の概略]
 本発明の実施形態について、図面を用いて説明を行う。図1は、本実施形態の熱成形装置10の全体を簡単に説明する模式側面図である。熱成形装置10は、シート加熱部20と、成形部30よりなる。シート加熱部20は、樹脂成形シートSを加熱する場所である。事前にワンショット分にカットされた樹脂成形シートSは搬送装置50によって図示しないクランプ機能によってクランプされ、シート加熱部20に移動される。シート加熱部20では、樹脂成形シートSを加熱して軟化させる。次に、成形部30に樹脂成形シートSを搬送して成形を行う。
[Outline of device configuration]
An embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a schematic side view briefly illustrating the entire thermoforming apparatus 10 of the present embodiment. The thermoforming apparatus 10 includes a sheet heating unit 20 and a molding unit 30. The sheet heating unit 20 is a place for heating the resin molded sheet S. The resin molded sheet S cut in advance for one shot is clamped by the transfer device 50 by a clamping function (not shown) and moved to the sheet heating unit 20. In the sheet heating unit 20, the resin molded sheet S is heated and softened. Next, the resin molding sheet S is conveyed to the molding unit 30 to perform molding.
 シート加熱部20には、一対のヒータユニットとして上側ヒータユニット21と下側ヒータユニット22が備えられている。上側ヒータユニット21と下側ヒータユニット22の間に搬送装置50にクランプされた樹脂成形シートSを搬送すると、上側ヒータユニット21と下側ヒータユニット22とに配置された発熱体に通電される。これにより樹脂成形シートSが加熱され、軟化される。加熱温度は樹脂成形シートSの素材によって適切に設定されている。 The sheet heating unit 20 is provided with an upper heater unit 21 and a lower heater unit 22 as a pair of heater units. When the resin molded sheet S clamped to the transport device 50 is transported between the upper heater unit 21 and the lower heater unit 22, the heating elements arranged in the upper heater unit 21 and the lower heater unit 22 are energized. As a result, the resin molded sheet S is heated and softened. The heating temperature is appropriately set by the material of the resin molded sheet S.
 成形部30には、上下動される上側テーブル31と下側テーブル32とが備えられている。上側テーブル31及び下側テーブル32には後述するボールネジ(第2ボールネジ34及び第1ボールネジ35)によって上下動する構成となっており、上側テーブル31の内部に備えられた上型37と下側テーブル32に備えられた下型33を近接させることによって、搬送装置50によって搬送した樹脂成形シートSの成形を行う構成となっている。 The molding unit 30 is provided with an upper table 31 and a lower table 32 that are moved up and down. The upper table 31 and the lower table 32 are configured to move up and down by ball screws (second ball screw 34 and first ball screw 35) described later, and the upper mold 37 and the lower table provided inside the upper table 31. By bringing the lower mold 33 provided in the 32 close to each other, the resin molded sheet S transported by the transport device 50 is molded.
[成形部の構成]
 次に成形部30の構成を具体的に説明する。図2に成形部30の側面図を示す。成形部30にはフレーム36が備えられ、フレーム36内で上側テーブル31と下側テーブル32とを昇降させる。フレーム36の下部であって下側テーブル32の四隅に対応する位置には、上下方向に長く下側テーブル32の昇降ストロークに対応した長さのガイドレール36aが設けられている。
[Structure of molded part]
Next, the configuration of the molding unit 30 will be specifically described. FIG. 2 shows a side view of the molded portion 30. The molding portion 30 is provided with a frame 36, and the upper table 31 and the lower table 32 are moved up and down in the frame 36. At the lower part of the frame 36, which corresponds to the four corners of the lower table 32, a guide rail 36a which is long in the vertical direction and has a length corresponding to the elevating stroke of the lower table 32 is provided.
 図3に、下側テーブル32の駆動系を抜き出して斜視図に示す。下側テーブル32には、その四隅に嵌合部32aが設けられている。この嵌合部32aは図2に示すガイドレール36aと嵌合することで、下側テーブル32の昇降をガイドする機能を有している。また、下側テーブル32の対角に第2ボールネジ34が配置される。第2ボールネジ34はフレーム36に回動可能に固定されており、下側テーブル32を貫通して配置されている。そして、下側テーブル32には第2ボールネジ34の貫通する位置にナット34bが固定されており、ナット34bと第2ボールネジ34が噛み合う構成となっている。 FIG. 3 shows a perspective view of the drive system of the lower table 32. The lower table 32 is provided with fitting portions 32a at its four corners. The fitting portion 32a has a function of guiding the raising and lowering of the lower table 32 by fitting with the guide rail 36a shown in FIG. Further, the second ball screw 34 is arranged diagonally to the lower table 32. The second ball screw 34 is rotatably fixed to the frame 36 and is arranged so as to penetrate the lower table 32. A nut 34b is fixed to the lower table 32 at a position where the second ball screw 34 penetrates, and the nut 34b and the second ball screw 34 mesh with each other.
 第2ボールネジ34の上端には、第2プーリ34aが取り付けられており、第2タイミングベルト34cを介して第2サーボモータ61の回転駆動力が第2プーリ34aそれぞれに伝達される。したがって、第2サーボモータ61の回転駆動によって、下側テーブル32は昇降する構成となっている。下側テーブル32の中央には下型33が固定されており、下型33も下側テーブル32の昇降にしたがって昇降する。 A second pulley 34a is attached to the upper end of the second ball screw 34, and the rotational driving force of the second servomotor 61 is transmitted to each of the second pulleys 34a via the second timing belt 34c. Therefore, the lower table 32 is configured to move up and down by the rotational drive of the second servomotor 61. A lower die 33 is fixed to the center of the lower table 32, and the lower die 33 also moves up and down as the lower table 32 moves up and down.
 図4に、上側テーブル31の駆動系を抜き出して斜視図に示している。上側テーブル31の四隅には把持部材31aが設けられている。把持部材31aは、図2に示すフレーム36に備えられたガイドレール36bと係合して摺動して、上側テーブル31の昇降をガイドする。上側テーブル31の上下駆動力は第1サーボモータ60によって得られ、第1サーボモータ60の回転力が図4に示される様に第1タイミングベルト35cによって第1ボールネジ35に伝達されることで、上側テーブル31を昇降させる。第1ボールネジ35の端部には第1プーリ35aが固定されている。上側テーブル31の下面には上型37が固定されている。 FIG. 4 shows a perspective view of the drive system of the upper table 31 extracted. Gripping members 31a are provided at the four corners of the upper table 31. The gripping member 31a engages with the guide rail 36b provided on the frame 36 shown in FIG. 2 and slides to guide the raising and lowering of the upper table 31. The vertical driving force of the upper table 31 is obtained by the first servomotor 60, and the rotational force of the first servomotor 60 is transmitted to the first ball screw 35 by the first timing belt 35c as shown in FIG. The upper table 31 is raised and lowered. A first pulley 35a is fixed to the end of the first ball screw 35. An upper die 37 is fixed to the lower surface of the upper table 31.
 図5に、上型37と下型33が近接した状態の側面断面図を示す。なお、上型37と下型33の待避位置よりも同図の上型37と下型33は近接した状態を示している。上型37に対して下型33は、樹脂成形シートSを挟んで当接する構成となっていて、上型37には、シート押圧部37aが備えられている。シート押圧部37aは、上型37に対してスプリング37bを介して係合されており、スプリング37bの中央に配置される図示しないシャフトでガイドされることで、後述する図7Dに示す通り上型37と下型33が当接した際には、シート押圧部37aは上型37に設けられた凹部37cに収納される。 FIG. 5 shows a side sectional view of the upper die 37 and the lower die 33 in close proximity to each other. The upper die 37 and the lower die 33 in the figure are closer to each other than the retreat positions of the upper die 37 and the lower die 33. The lower mold 33 is configured to abut against the upper mold 37 with the resin molded sheet S sandwiched between them, and the upper mold 37 is provided with a sheet pressing portion 37a. The seat pressing portion 37a is engaged with the upper mold 37 via a spring 37b, and is guided by a shaft (not shown) arranged in the center of the spring 37b, so that the upper mold is as shown in FIG. 7D described later. When the 37 and the lower mold 33 come into contact with each other, the sheet pressing portion 37a is housed in the recess 37c provided in the upper mold 37.
[動作の説明]
 本実施形態の熱成形装置10では上記構成であるために、次に説明するような動作によって樹脂成形シートSの成形を行う。図6に、成形部30に関する制御の概略構成を示す。プログラマブルロジックコントローラ(以下PLC)90には、サーボモータ制御部91、入力部94、出力部95が接続されている。また、サーボモータ制御部91には第1サーボモータ60及び第2サーボモータ61がそれぞれ接続されている。また、第1サーボモータ60には第1エンコーダ70が、第2サーボモータ61には第2エンコーダ71が接続され、第1エンコーダ70及び第2エンコーダ71はPLC90にそれぞれ接続されている。
[Explanation of operation]
Since the thermoforming apparatus 10 of the present embodiment has the above configuration, the resin molded sheet S is molded by the operation as described below. FIG. 6 shows a schematic configuration of control regarding the molded portion 30. A servomotor control unit 91, an input unit 94, and an output unit 95 are connected to the programmable logic controller (hereinafter referred to as PLC) 90. Further, the first servomotor 60 and the second servomotor 61 are connected to the servomotor control unit 91, respectively. Further, a first encoder 70 is connected to the first servomotor 60, a second encoder 71 is connected to the second servomotor 61, and the first encoder 70 and the second encoder 71 are connected to the PLC 90, respectively.
 ここで、出力部95は図示しない操作パネルに備えるディスプレイ等からなり、エラーなどのステータスを表示する。入力部94は図示しない操作パネルに供えるボタンからなり、種々のデータなどを入力可能になっている。なお、操作パネルはタッチパネル方式として、入力部94と出力部95を兼ねることを妨げない。また、入力部94は別途操作用のボタンを備えても良い。また、サーボモータ制御部91は、第1サーボモータ60及び第2サーボモータ61を駆動制御する。なお、PLC90にはその他、成形部30に備える機器が接続されるが、本発明に直接関係しないので、説明を割愛する。 Here, the output unit 95 includes a display or the like provided on an operation panel (not shown), and displays a status such as an error. The input unit 94 includes buttons provided on an operation panel (not shown), and can input various data and the like. The operation panel is a touch panel system and does not prevent the input unit 94 and the output unit 95 from being combined. Further, the input unit 94 may be provided with a button for operation separately. Further, the servomotor control unit 91 drives and controls the first servomotor 60 and the second servomotor 61. In addition, although a device provided in the molding unit 30 is connected to the PLC 90, the description thereof is omitted because it is not directly related to the present invention.
 図7A乃至図7Dに、上型37と下型33によって樹脂成形シートSを成形する様子を模式的に示す。図7Aでは、樹脂成形シートSを上型37に備えられたシート押圧部37aによって下型33に対して押さえつける。シート押圧部37aはスプリング37bによって付勢されており、その押圧力により樹脂成形シートSが移動しないように固定する。この際に、樹脂成形シートSは、搬送装置50によってその一端がクランプされている。 7A to 7D schematically show how the resin molded sheet S is molded by the upper mold 37 and the lower mold 33. In FIG. 7A, the resin molded sheet S is pressed against the lower mold 33 by the sheet pressing portion 37a provided on the upper mold 37. The sheet pressing portion 37a is urged by a spring 37b, and the resin molded sheet S is fixed so as not to move due to the pressing force. At this time, one end of the resin molded sheet S is clamped by the transport device 50.
 そして、図7Bに示すように、下型33に対して上型37を前進させることで、樹脂成形シートSを変形させていく。図7Cに示すように下型33に対する上型37の距離が近くなるほどスプリング37bは圧縮され、樹脂成形シートSを保持し続ける。そして、図7Dに示すように上型37と下型33が樹脂成形シートSを介して密着する位置まで前進させることで、樹脂成形シートSを加圧・変形させる。こうして、上型37と下型33によって樹脂成形シートSが成形品Mに成形される。 Then, as shown in FIG. 7B, the resin molded sheet S is deformed by advancing the upper mold 37 with respect to the lower mold 33. As shown in FIG. 7C, the closer the distance of the upper mold 37 to the lower mold 33 is, the more the spring 37b is compressed and the resin molded sheet S is continuously held. Then, as shown in FIG. 7D, the upper mold 37 and the lower mold 33 are advanced to a position where they are in close contact with each other via the resin molded sheet S, thereby pressurizing and deforming the resin molded sheet S. In this way, the resin molded sheet S is molded into the molded product M by the upper mold 37 and the lower mold 33.
[作用効果の説明]
 本実施形態の熱成形装置10は、上記構成であるため、以下に示すような作用及び効果を奏する。
[Explanation of action and effect]
Since the thermoforming apparatus 10 of the present embodiment has the above configuration, it exhibits the following actions and effects.
 まず、樹脂成形シートSの特定の部位を、押圧手段であるシート押圧部37aによって押さえてから成形をすることで、押さえた部分の内部に歪みを貯めにくくすることができる。これは、成形型として上型37と下型33を備え、上型37と下型33の間に加熱した樹脂成形シートSを挟んで成形する熱成形装置10において、上型37または下型33のうちいずれか一方側の成形面から突出するように備えられる押圧手段であるシート押圧部37aを備え、シート押圧部37aは、樹脂成形シートSのうち成形後の成形品Mの一部となる特定の部位(後述する透明部M1)を他方側の成形型の成形面と挟み込むようにして押さえ(本実施形態では上型37に備えられたシート押圧部37aの下面と下型33の上面で挟み込むようにして押さえ)、樹脂成形シートSのうち特定の部位以外を上型37と下型33によって挟み込み、樹脂成形シートSを成形することによる。 First, by pressing a specific portion of the resin molded sheet S with the sheet pressing portion 37a, which is a pressing means, and then molding, it is possible to make it difficult for strain to be accumulated inside the pressed portion. This is a thermoforming apparatus 10 provided with an upper mold 37 and a lower mold 33 as a molding mold and sandwiching a heated resin molding sheet S between the upper mold 37 and the lower mold 33, in which the upper mold 37 or the lower mold 33 is formed. A sheet pressing portion 37a, which is a pressing means provided so as to protrude from the molded surface on either one of the two, is provided, and the sheet pressing portion 37a becomes a part of the molded product M after molding in the resin molded sheet S. A specific portion (transparent portion M1 described later) is pressed so as to be sandwiched between the molding surface of the molding die on the other side (in the present embodiment, the lower surface of the sheet pressing portion 37a provided on the upper die 37 and the upper surface of the lower die 33 are pressed. (Holding so as to be sandwiched), the resin molded sheet S is formed by sandwiching the resin molded sheet S with the upper mold 37 and the lower mold 33 except for a specific portion.
 図8A乃至図8Dに、比較のために用意した、上型137と下型133によって樹脂成形シートSが成形される様子を模式的に示した図である。上型137と下型133で樹脂成形シートSを成形する構成となっている。なお、上型137と下型133は、本実施形態の上型37と下型33と同じ役割を果たす。移動装置150によって一端をクランプされている点も同様である。樹脂成形シートSは本実施形態と同様に上型137と下型133をお互いに近接させることで成形を行う。しかしながら図8Bに示すように樹脂成形シートSは、上型137とポイントP1で当接し、下型133とポイントP3で当接することで、下型133から浮き上がるポイントP2ができる。 8A to 8D are diagrams schematically showing how the resin molded sheet S is molded by the upper mold 137 and the lower mold 133 prepared for comparison. The resin molding sheet S is molded by the upper mold 137 and the lower mold 133. The upper mold 137 and the lower mold 133 play the same role as the upper mold 37 and the lower mold 33 of the present embodiment. The same applies to the point that one end is clamped by the moving device 150. The resin molded sheet S is molded by bringing the upper mold 137 and the lower mold 133 close to each other as in the present embodiment. However, as shown in FIG. 8B, the resin molded sheet S abuts on the upper die 137 at the point P1 and abuts on the lower die 133 at the point P3 to form a point P2 floating from the lower die 133.
 そして、図8Cに示すように下型133に対して樹脂成形シートSが当接するポイントP4が増えて、このまま上型137と下型133を近接させて樹脂成形シートSが成形される結果となる。しかしながら、ポイントP2は更に浮いた状態で上から上型137によって押し潰されることになる一方で、先にポイントP1とポイントP3に当接した状態で上型137と下型133が近接するため、結果的にポイントP1とポイントP3の間で樹脂成形シートSが伸ばされるような力が作用し、ポイントP2では樹脂成形シートSが圧縮されるような力が作用する。もちろん、図8Dにて型締めされることになるため、均一な厚みの成形品Mが出来上がる結果になるが、その成形品Mの内部で歪みが蓄積される結果になる。 Then, as shown in FIG. 8C, the number of points P4 at which the resin molding sheet S abuts on the lower mold 133 increases, resulting in the resin molding sheet S being molded with the upper mold 137 and the lower mold 133 in close proximity to each other. .. However, while the point P2 is further floated and crushed by the upper die 137 from above, the upper die 137 and the lower die 133 are close to each other in the state where the point P1 and the point P3 are in contact with each other first. As a result, a force that stretches the resin molded sheet S acts between the points P1 and P3, and a force that compresses the resin molded sheet S acts at the point P2. Of course, since the molding is performed in FIG. 8D, the result is that the molded product M having a uniform thickness is completed, but the strain is accumulated inside the molded product M.
 一方、本発明の場合には、上型37と下型33を近接させる前に、図7A乃至図7Dに示した様にシート押圧部37aによって下型33に対して樹脂成形シートSを押さえつける。図9に、上型と下型を用いて樹脂成形シートの成形を行う場合の斜視図を模式的に示す。成形品Mには、透明部M1が設けられており、製品となった際に例えば成形品Mが製品に用いられた場合に、その後ろ側に表示画面を配置するなどし、透明部M1が窓部分となる。 On the other hand, in the case of the present invention, the resin molded sheet S is pressed against the lower mold 33 by the sheet pressing portion 37a as shown in FIGS. 7A to 7D before the upper mold 37 and the lower mold 33 are brought close to each other. FIG. 9 schematically shows a perspective view when molding a resin molded sheet using an upper mold and a lower mold. The molded product M is provided with a transparent portion M1. When the molded product M is used in the product, for example, a display screen is arranged behind the molded product M, so that the transparent portion M1 is provided. It becomes the window part.
 このような成形品Mは、シート押圧部37aによって透明部M1部分を最初に下型33に対して押圧し、保持した状態で下型33に対して上型37を近接させる(実際には上型37は第1サーボモータ60を駆動させることで降下させ、下型33は第2サーボモータ61を駆動させることで上昇させ、お互いに近接させる制御となる)。そして、図7Dに示すように上型37と下型33とを樹脂成形シートSを介して密着させることで、成形品Mを成形する。 In such a molded product M, the transparent portion M1 is first pressed against the lower mold 33 by the sheet pressing portion 37a, and the upper mold 37 is brought close to the lower mold 33 while being held (actually, the upper mold 37). The mold 37 is lowered by driving the first servomotor 60, and the lower mold 33 is raised by driving the second servomotor 61, so that the mold 37 is controlled to be close to each other). Then, as shown in FIG. 7D, the upper mold 37 and the lower mold 33 are brought into close contact with each other via the resin molding sheet S to form the molded product M.
 このようにして成形品Mを成形することで、最初にシート押圧部37aで透明部M1部分がしっかりと下型33の上面に対して圧力を加えて保持することができ、図7B、図7Cと樹脂成形シートSが変形されていく時に、透明部M1は動かない。このために、図8B及び図8Cに示すようなポイントP2に示すような浮き上がりができない。したがって、この透明部M1から肉が引っ張られたりしわが寄ったりということがなく成形されることとなり、図7Dの状態になったときに透明部M1部分に内部歪みが蓄積されていない状態で成形可能となる。 By molding the molded product M in this way, the transparent portion M1 can be firmly held by applying pressure to the upper surface of the lower mold 33 at the sheet pressing portion 37a first, and FIGS. 7B and 7C And when the resin molded sheet S is deformed, the transparent portion M1 does not move. Therefore, the floating as shown at the point P2 as shown in FIGS. 8B and 8C cannot be performed. Therefore, the meat is molded without being pulled or wrinkled from the transparent portion M1, and when the state shown in FIG. 7D is reached, the transparent portion M1 is molded in a state where internal strain is not accumulated. It will be possible.
 このような透明部M1に生じる内部歪みが生じた場合、目視しただけではその有無を判断することは難しいが、透明部M1の背面に光源を配置することで、干渉縞となって目視できる。例えば、先述したように表示画面を映す窓として透明部M1を利用するケースでは、課題で言及した通り内部歪みの影響によって角度によって見えにくい部分が出来るなどの不具合となって現れることになる。 When such internal distortion occurs in the transparent portion M1, it is difficult to determine the presence or absence thereof only by visual inspection, but by arranging a light source on the back surface of the transparent portion M1, it can be visually recognized as interference fringes. For example, in the case where the transparent portion M1 is used as the window for displaying the display screen as described above, as mentioned in the problem, a portion that is difficult to see depending on the angle is formed due to the influence of the internal distortion.
 また、課題で言及したように、内部歪みが方向性を持って形成されることで、透過光に対して偏光性を示すことがあり、例えば偏光レンズを用いたサングラスを用いた場合に、透明部M1を透過して見える表示画面の一部が欠損して見えるような不具合となって現れることがある。しかし、透明部M1をシート押圧部37aで押さえた状態で上型37と下型33で成形を行うことで、こうした問題を解決することが可能となる。 In addition, as mentioned in the task, the internal strain is formed in a directional manner, so that it may exhibit polarization with respect to transmitted light. For example, when sunglasses using a polarized lens are used, it is transparent. A part of the display screen that can be seen through the portion M1 may appear as a defect. However, such a problem can be solved by molding with the upper mold 37 and the lower mold 33 in a state where the transparent portion M1 is pressed by the sheet pressing portion 37a.
 また、このようなシート押圧部37aによって押さえられた状態で樹脂成形シートSが成形されるために、この部分にエア溜まりが発生し易い形状であったとしても、シート押圧部37aによって押さえられることでエア溜まりが生じることを防ぐことができる。このため、エア溜まりの発生による外観不良を防ぐことが可能となる。透明部M1が製品となったときに窓として使われる場合、この部分にエア溜まりが生じやすい構造であったとしても、エア溜まりが生じることによる外観不良を防ぐことが可能である。 Further, since the resin molded sheet S is molded in a state of being pressed by the sheet pressing portion 37a, even if the shape is such that air accumulation is likely to occur in this portion, the resin molded sheet S is pressed by the sheet pressing portion 37a. It is possible to prevent the formation of air pools. Therefore, it is possible to prevent the appearance from being deteriorated due to the generation of air pool. When the transparent portion M1 is used as a window when it is made into a product, it is possible to prevent an appearance defect due to the occurrence of air accumulation even if the structure is such that air accumulation is likely to occur in this portion.
 また、同様に樹脂成形シートSのシート押圧部37aに押さえられる部分に、穴加工が予めされているようなケースでは、穴部分が伸びて変形したり、サイズが変わったりといった影響を避けることができる。また、樹脂成形シートSのシート押圧部37aに予め印刷がなされている場合には、印刷部分がずれたり、伸びて変形したりするなどの影響を避けることができる。 Similarly, in a case where a hole is preliminarily formed in the portion of the resin molded sheet S to be pressed by the sheet pressing portion 37a, it is possible to avoid the influence that the hole portion is stretched and deformed or the size is changed. can. Further, when the sheet pressing portion 37a of the resin molded sheet S is printed in advance, it is possible to avoid the influence of the printed portion being displaced, stretched and deformed.
 また、熱成形装置10は、位置制御またはトルク制御を行っているため、上型37と下型33との間を適切なクリアランスにコントロールすることが出来る。これは、上型37を上昇させる第1駆動機構に相当する第1サーボモータ60と、下型33を下降させる第2駆動機構に相当する第2サーボモータ61と、第1サーボモータ60及び第2サーボモータ61を制御する制御装置となるサーボモータ制御部91を備え、上型37と下型33を閉じた状態で、第1サーボモータ60及び第2サーボモータ61を制御するサーボモータ制御部91によって位置制御またはトルク制御を行い、上型37に対する下型33の位置を制御しているためである。 Further, since the thermoforming apparatus 10 performs position control or torque control, it is possible to control the clearance between the upper die 37 and the lower die 33 to an appropriate level. This includes a first servomotor 60 corresponding to a first drive mechanism for raising the upper die 37, a second servomotor 61 corresponding to a second drive mechanism for lowering the lower die 33, a first servomotor 60, and a first servomotor 60. 2 Servo motor control unit 91, which is a control device for controlling the servo motor 61, and controls the first servo motor 60 and the second servo motor 61 with the upper die 37 and the lower die 33 closed. This is because the position control or torque control is performed by the 91 to control the position of the lower die 33 with respect to the upper die 37.
 上側テーブル31及び下側テーブル32を駆動するためにはそれぞれ第1サーボモータ60及び第2サーボモータ61を用いてフィードバック制御を行いながら駆動を行っている。このサーボモータ(第1サーボモータ60及び第2サーボモータ61)の回転駆動によって、ボールネジ(第1ボールネジ35及び第2ボールネジ34)が回転され、結果的に上側テーブル31及び下側テーブル32を昇降できる構成となっている。この時に例えば上側テーブル31であれば、第1サーボモータ60は上側テーブル31の位置をフィードバック要素とした位置制御と、発生トルクをフィードバック要素としたトルク制御が実行可能である。同様に下側テーブル32に関しても位置制御とトルク制御を行うことが可能である。 In order to drive the upper table 31 and the lower table 32, the first servomotor 60 and the second servomotor 61 are used to drive while performing feedback control, respectively. The ball screw (first ball screw 35 and second ball screw 34) is rotated by the rotational drive of the servo motors (first servo motor 60 and second servo motor 61), and as a result, the upper table 31 and the lower table 32 are moved up and down. It is a structure that can be done. At this time, for example, in the case of the upper table 31, the first servomotor 60 can execute position control using the position of the upper table 31 as a feedback element and torque control using the generated torque as a feedback element. Similarly, position control and torque control can be performed on the lower table 32 as well.
 この結果、型締め時に位置制御またはトルク制御を行うことができ、上型37と下型33とのクリアランスをコントロールすることが可能となる。型締め圧力は樹脂成形シートSの厚みや素材の性質によって、或いは上型37と下型33の加温条件などによって、変更が望ましい場合がある。樹脂成形シートSは事前に加熱部20で加熱されて軟化している状態であるとはいえ、成形加工後にスプリングバックが発生するケースがある。こうしたケースでは、上型37と下型33に対して位置制御またはトルク制御を行うことで、成形品Mの成形精度を向上せることに寄与することができる。 As a result, position control or torque control can be performed at the time of mold clamping, and the clearance between the upper mold 37 and the lower mold 33 can be controlled. It may be desirable to change the mold clamping pressure depending on the thickness of the resin molded sheet S, the properties of the material, the heating conditions of the upper mold 37 and the lower mold 33, and the like. Although the resin molded sheet S is in a state of being preheated by the heating unit 20 and softened in advance, there are cases where springback occurs after the molding process. In such a case, by performing position control or torque control on the upper mold 37 and the lower mold 33, it is possible to contribute to improving the molding accuracy of the molded product M.
 そして、こうした位置制御を行うにあたって、上型37や下型33の停止位置などを入力部94によって数値で入力して設定できる構成とすることが好ましい。そうすることで、異なる成形品Mを熱成形装置10で成形する場合に、樹脂成形シートSの特性やその他の条件によって、細かな条件調整が可能となり、結果的に成形品Mが出来上がった際の成形精度の向上に繋がる。もちろん、そうした数値設定は図示しない記憶手段によって記憶させ、成形品M毎に選んで変更できるようにすることを妨げない。 Then, in performing such position control, it is preferable to have a configuration in which the stop positions of the upper die 37 and the lower die 33 can be numerically input and set by the input unit 94. By doing so, when different molded products M are molded by the thermoforming apparatus 10, fine condition adjustment is possible depending on the characteristics of the resin molded sheet S and other conditions, and as a result, when the molded product M is completed. It leads to the improvement of molding accuracy. Of course, such numerical settings are stored by a storage means (not shown), and do not prevent the molded product M from being selected and changed.
 以上、本発明に係る熱成形装置10に関する説明をしたが、本発明はこれに限定されるわけではなく、その趣旨を逸脱しない範囲で様々な変更が可能である。例えば、本実施形態では上型37にシート押圧部37aを設ける構成としたが、押さえる場所によってはシート押圧部37aを下型33に設けた方が良い場合もあるので、そうした変更を妨げない。また、本実施形態では上型37とシート押圧部37aの間にスプリング37bを設けることで、樹脂成形シートSに対して付勢しているが、例えばシリンダを用いた付勢手段や、モータを用いた付勢手段を採用することを妨げない。この場合、上型37(或いは下型33)とシート押圧部37aを分離した型とすることもできる。 Although the thermoforming apparatus 10 according to the present invention has been described above, the present invention is not limited to this, and various changes can be made without departing from the spirit of the present invention. For example, in the present embodiment, the seat pressing portion 37a is provided on the upper mold 37, but it may be better to provide the seat pressing portion 37a on the lower mold 33 depending on the place to be pressed, so that such a change is not hindered. Further, in the present embodiment, the spring 37b is provided between the upper die 37 and the seat pressing portion 37a to urge the resin molded sheet S. For example, an urging means using a cylinder or a motor may be used. It does not prevent the adoption of the used urging means. In this case, the upper die 37 (or the lower die 33) and the sheet pressing portion 37a may be separated from each other.
 また、上側テーブル31及び下側テーブル32の移動方法に関しても、ボールネジ(第1ボールネジ35及び第2ボールネジ34)をサーボモータ(第1サーボモータ60及び第2サーボモータ61)の回転駆動を、動力伝達手段であるタイミングベルト(第1タイミングベルト35c及び第2タイミングベルト34c)とプーリ等(第1プーリ35a及び第2プーリ34a)を介して駆動される方法としているが、これに限定されることはなく、例えば動力伝達手段として歯車やカムなどを併用して駆動することを妨げない。また、上型37と下型33との型締めにシリンダやクランク機構を併用することを妨げない。 Further, regarding the method of moving the upper table 31 and the lower table 32, the ball screw (first ball screw 35 and second ball screw 34) is driven by the rotational drive of the servomotor (first servomotor 60 and second servomotor 61). The method is to be driven via a timing belt (first timing belt 35c and second timing belt 34c) which is a transmission means and a pulley or the like (first pulley 35a and second pulley 34a), but the method is limited to this. For example, it does not prevent the vehicle from being driven by using a gear or a cam as a power transmission means. Further, it does not prevent the cylinder and the crank mechanism from being used together for the mold clamping between the upper mold 37 and the lower mold 33.
 また、上側テーブル31及び下側テーブル32を駆動する熱成形装置10として説明したが、必要に応じて片側固定、つまり上側テーブル31または下側テーブル32のいずれか一方を固定として、他方だけ駆動する方法としても良い。 Further, although the thermoforming apparatus 10 for driving the upper table 31 and the lower table 32 has been described, it is fixed on one side as necessary, that is, either the upper table 31 or the lower table 32 is fixed and only the other is driven. It may be a method.
10   熱成形装置
33   下型
37   上型
37a  シート押圧部
S    樹脂成形シート
M    成形品
10 Thermoforming device 33 Lower mold 37 Upper mold 37a Sheet pressing part S Resin molded sheet M Molded product

Claims (5)

  1.  成形型として上型と下型を備え、前記上型と前記下型の間に加熱した樹脂製シートを挟んで成形する熱成形装置において、
     前記上型または前記下型のうちいずれか一方側の成形面から突出するように備えられる押圧手段を有し、
     前記押圧手段は、前記樹脂製シートのうち成形後の成形品の一部となる特定の部位を他方側の前記成形型の成形面と挟み込む機能を有し、
     前記樹脂製シートのうち前記特定の部位以外を前記上型と前記下型によって挟み込み、前記樹脂製シートを成形すること、
       を特徴とする熱成形装置。
    In a thermoforming apparatus having an upper mold and a lower mold as a molding mold and sandwiching a heated resin sheet between the upper mold and the lower mold.
    It has a pressing means provided so as to protrude from the molding surface on either one of the upper mold and the lower mold.
    The pressing means has a function of sandwiching a specific portion of the resin sheet, which is a part of the molded product after molding, with the molding surface of the molding mold on the other side.
    The resin sheet is formed by sandwiching a portion other than the specific portion of the resin sheet between the upper mold and the lower mold.
    A thermoforming device characterized by.
  2.  請求項1に記載の熱成形装置において、
     前記特定の部位が、前記樹脂製シートが製品となった時に透明な部分であること、
       を特徴とする熱成形装置。
    In the thermoforming apparatus according to claim 1,
    The specific part is a transparent part when the resin sheet becomes a product.
    A thermoforming device characterized by.
  3.  請求項1または請求項2に記載の熱成形装置において、
     前記上型または前記下型の少なくとも一方を昇降させる駆動機構と、
     前記駆動機構を制御する制御装置を備え、
     前記上型と前記下型を閉じた状態で、前記駆動機構を制御する制御装置によって位置制御またはトルク制御を行い、前記上型に対する前記下型の位置を制御すること、
       を特徴とする熱成形装置。
    In the thermoforming apparatus according to claim 1 or 2.
    A drive mechanism that raises and lowers at least one of the upper mold and the lower mold, and
    A control device for controlling the drive mechanism is provided.
    With the upper mold and the lower mold closed, position control or torque control is performed by a control device that controls the drive mechanism to control the position of the lower mold with respect to the upper mold.
    A thermoforming device characterized by.
  4.  請求項1に記載の熱成形装置において、
     前記特定の部位が、成形時にエア溜まりを生じやすい部分であること、
       を特徴とする熱成形装置。
    In the thermoforming apparatus according to claim 1,
    The specific part is a part where air accumulation is likely to occur during molding.
    A thermoforming device characterized by.
  5.  成形型として上型と下型を備え、前記上型と前記下型の間に加熱した樹脂製シートを挟んで成形する熱成形方法において、
     前記上型または前記下型のうちいずれか一方側の成形面から突出するように備えられる押圧手段と、他方側の前記成形型の成形面とで、前記樹脂製シートのうち成形後の成形品の一部となる特定の部位を挟み込み、
     前記上型と前記下型とで、前記樹脂製シートのうち前記特定の部位以外を挟み込み、前記樹脂製シートを成形すること、
       を特徴とする熱成形方法。
    In a thermoforming method in which an upper mold and a lower mold are provided as molding molds, and a heated resin sheet is sandwiched between the upper mold and the lower mold.
    A molded product of the resin sheet after molding, with a pressing means provided so as to protrude from the molding surface on either one of the upper mold and the lower mold, and the molding surface of the molding mold on the other side. By sandwiching a specific part that becomes a part of
    Forming the resin sheet by sandwiching a portion other than the specific portion of the resin sheet between the upper mold and the lower mold.
    A thermoforming method characterized by.
PCT/JP2021/022473 2020-06-12 2021-06-14 Thermoforming device and thermoforming method WO2021251502A1 (en)

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Country Link
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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH03126619U (en) * 1990-03-31 1991-12-20
JPH07186252A (en) * 1993-12-25 1995-07-25 Meiwa Ind Co Ltd Manufacture of laminated molded article attached with decorative material

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH03126619U (en) * 1990-03-31 1991-12-20
JPH07186252A (en) * 1993-12-25 1995-07-25 Meiwa Ind Co Ltd Manufacture of laminated molded article attached with decorative material

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JP2021194834A (en) 2021-12-27
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